Folding structure with improved locking system

ABSTRACT

The present invention is a folding structure having an improved locking mechanism. In one embodiment, the folding structure comprises a plurality of legs and a hinge mechanism, the hinge mechanism comprising a plug hinge removably connected to a slider hinge between a first position at which the structure is substantially collapsed and a second position at which the structure is substantially open and the plug hinge is locked to the slider hinge. The hinge mechanism may further comprise a release cap engaged with the slider hinge and having a pair of buttons. Depression of the buttons unlocks or releases the plug hinge from the slider hinge, allowing the folding structure to be collapsed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 60/672,889 filed on Apr. 19, 2005, now pending, which is herebyincorporated by reference in its entirety into this specification.

BACKGROUND OF THE INVENTION

Folding structures, such as tents and cabanas, utilize variousmechanisms to hold the structure in the open or unfolded position. U.S.Pat. Nos. 2,864,389; 4,945,936; and 6,021,795 each disclose what iscommonly referred to as an “umbrella” type folding structure. Thefolding structures described in those patents employ a hinge mechanismconsisting of a lower hub that is manually moved upwards into engagementwith an upper hub to unfold a plurality of legs to open the structure.In those conventional devices, the lower and upper hubs are not securedor locked together when the folding structure is open, leading to apotential unwanted collapse of the folding structure.

SUMMARY OF THE INVENTION

One object of the present invention is to provide a folding structurefor use as a cabana, tent, or the like that employs a more positive andsecure hinge mechanism to provide safer and quicker folding of thestructure.

The present invention is directed to a folding structure for use as acabana, tent, or the like. In one embodiment, the folding structurecomprises a plurality of legs and a hinge mechanism comprising a plughinge removably connected to a slider hinge between a first positionwhere the structure is substantially collapsed and a second positionwhere the structure is substantially open and the plug hinge is lockedto the slider hinge. The plug hinge comprises a pair of flexible tabshaving ridge portions that ride on a tapered wall of the slider hinge asthe plug hinge is brought into engagement with the slider hinge. Uponcomplete engagement of the plug hinge with the slider hinge, the ridgeportions of the flexible tabs snap into locked engagement with a lipportion of the slider hinge. The hinge mechanism may further comprise arelease cap having a pair of buttons that, when pressed, contact andmove the ridge portions of the flexible tabs off the lip portion todisengage the plug hinge from the slider hinge, whereby the foldingstructure may be collapsed. Snap engagement of the ridge portions of theflexible tabs of the plug hinge with the lip portion of the slider hingeprovide a positive and secure hinge mechanism to maintain the structurein the open position. The buttons on the release cap provide a fast andeasy means to release or disengage the plug hinge from the slider hingeand thus collapse the structure.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description of the invention will be more fully understoodwith reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of the folding structure according to thepresent invention shown in an open or erect position and having a fabricenclosure attached thereto for use as a cabana, tent or the like;

FIG. 2 is a cut-away perspective view of the folding structure in apartially folded or collapsed position wherein a plug hinge of a hingemechanism is fully disengaged from a slider hinge of the hingemechanism,

FIG. 3 is an exploded view of the hinge mechanism;

FIG. 4 is a perspective view of the upper portion of folding structurein a substantially collapsed or folded position, with the plug hingefully disengaged from the slider hinge;

FIG. 5 a perspective view of the top portion of the folding structure inan open or erect position with the plug hinge in secured or lockedengagement with the slider hinge;

FIG. 6 is a partial cut-away perspective view of the folding structureshowing the plug hinge disengaged from the slider hinge;

FIG. 7 is a partial cut-away perspective view of the folding structureshowing the plug hinge of the hinge mechanism in secured or lockedengagement with the slider hinge;

FIG. 8 is an enlarged view of Section A of FIG. 7;

FIG. 9 is a cross-sectional view of a retaining plug showing endportions of a rope tied into a knot that is securely retained within theretaining plug;

FIG. 10 is a perspective view of the plug hinge;

FIG. 11 is a front elevational view of the plug hinge;

FIG. 12 is a side elevational view of the plug hinge;

FIG. 13 is a top plan view of the plug hinge;

FIG. 14 is a cross-sectional view taken along line A-A of FIG. 13;

FIG. 15 is a perspective view of the slider hinge;

FIG. 16 is a front elevational view of the slider hinge;

FIG. 17 is a top plan view of the slider hinge;

FIG. 18 is a cross-sectional view taken along line B-B of FIG. 17;

FIG. 19 is a perspective view of the release cap;

FIG. 20 is a front elevational view of the release cap;

FIG. 21 is a top plan view of the release cap; and

FIG. 22 is a cross-sectional view taken along line A-A of FIG. 21.

DESCRIPTION OF THE INVENTION

Referring to FIG. 1-5, the present invention is directed to a device orstructure 10 that may be easily manipulated between an open and lockedposition (FIG. 1) and a folded or collapsed position (FIG. 2). Foldingstructure 10 generally comprises legs 28, 30, 32, and 34 (FIG. 4)pivotally connected to a hinge mechanism 52 (FIG. 1). As best seen inFIG. 2, each of legs 28, 30, 32, and 34 comprise an upper leg section 36connected to a lower leg section 38 by a hinge 40 that allows the lowerleg section 38 to be folded upon upper leg section 36 in a conventionalfashion. As best shown by FIGS. 4 and 5, folding structure 10 furthercomprises extending arms 44, 46, 48, and 50 each having an outer endpivotally connected to the sliding hinge 42 on the upper leg section 36and an inner end pivotally connected to a plug hinge 54 (to bedescribed) of the hinge mechanism 52. Folding structure 10 may include afabric enclosure 12 for use as a cabana, tent, or the like. As shown inFIG. 1, fabric enclosure 12 may comprise, for example, a front panel 14having a flap 16, a side panel 20, and (as shown in FIG. 2) side andrear panels 18 and 23, and a floor panel 22. Fabric enclosure 12 may beattached to folding structure 10 by a plurality of straps 24, inconventional fashion (FIG. 1). As best shown in FIG. 3, the hingemechanism 52 generally comprises a plug hinge 54, a slider hinge 70, anda release cap 88. As will be described more fully below, the plug hinge54 is moveable between a first position, with the folding structure 10open or erect and the plug hinge 54 locked with the slider hinge 70(FIGS. 1 and 5), and a second position, with the folding structure 10partially or fully collapsed and the plug hinge fully disengaged fromthe slider hinge (FIGS. 2 and 4). The release cap 88 may be engaged withthe slider hinge 70 and comprise first and second buttons 92 and 94. Aswill be described more fully below, depressing the buttons 92 and 94unlocks or releases the plug hinge 54 from the slider hinge 70, allowingthe folding structure 10 to be folded or collapsed. The hinge mechanism52 may further comprise a rope 106 attached to plug hinge 54, which maybe pulled to bring the plug hinge 54 into locked engagement with theslider hinge 70.

Referring to FIGS. 6 and 10-14, plug hinge 54 comprises a base portion56 (FIG. 10) and a plurality of mounting flanges 66 extending outwardlyfrom and formed as part of the base portion 56. Mounting flanges 66 arepivotally connected with the extending arms 44, 46, 48, and 50 byconventional means such as fittings and pins. Plug hinge 54 furthercomprises first and second tab portions 58 and 62 extending upwardlyfrom and formed as part of the base portion 56. As best shown by FIG.14, first and second tab portions 58 and 62 comprise tapered walls 59and 63, respectively. First and second tab portions 58 and 62 furthercomprise an annular-shaped protrusion or ridge portion 60 and 64,respectively, disposed upon the tapered walls 59 and 63, respectively.As will be described more fully below, upon complete engagement of plughinge 54 with slider hinge 70, ridge portions 60 and 64 are flexed andsnap into secure or locked engagement with a lip portion 82 (to bedescribed) of slider hinge 70.

Referring to FIGS. 6-8 and 15-18, slider hinge 70 comprises a bodyportion 72 (FIG. 15) having a lower end portion 74, an upper end portion76, and an internal passage-way or thru-hole 78. Thru-hole 78 isprovided to receive first and second tab portions 58 and 62 of plughinge 54. As shown in FIG. 18, thru-hole 78 has a tapered annular innerwall 80 adapted to receive and mate with tapered walls 59 and 63 offirst and second tab portions 58 and 62 of plug 54. As best shown byFIG. 15, slider hinge 70 further comprises an annular-shaped lip or rimportion 82 formed at upper end portion 76 of base portion 72. Sliderhinge 70 further comprises mounting flanges 84 adapted to pivotallyconnect with the upper portions of upper leg sections 36 of legs 28, 30,32, and 34. Slider hinge 70 further comprises a plurality of mountingprotrusions or tabs 86 disposed at lower end portion 74 of body portion72. As will be described more fully below, and as shown in FIGS. 3 and15, tabs 84 serve as a means for securely mounting release cap 88 onslider hinge 70. As plug hinge 54 is brought into engagement with sliderhinge 70, the ridge portions 60 and 64 of the tab portions 58 and 62ride upon the tapered wall 80 of the slider hinge 70, causing the tabportions 58 and 62 to become deflected and biased.(Not shown in thedrawings). As best shown by FIGS. 7 and 8, upon complete engagement ofplug hinge 54 with slider hinge 70, ridge portions 60 and 64 of tabportions 58 and 62 snap into locked engagement with lip portion 82 ofslider hinge 77, securing and locking hinge mechanism 54 in place inorder to maintain the structure 10 in the open position.

Referring to FIGS. 6-8 and 19-22, release cap 88 comprises a housingportion 90 and two opposing flexible and resilient push buttons 92 and94 formed as part of housing portion 90. Each of buttons 92 and 94comprises an inner wall portion 96 and an outer wall portion 98 [FIG.22]. Release cap 88 further comprises a pair of mounting slots 102adapted to engage with mounting tabs 86 of slider hinge 70 to securerelease cap 88 to slider hinge 70 [FIG. 15]. Release cap 88 furthercomprises a pair of rope openings 104 formed at the top of mountingslots 102. As seen in FIG. 8, depression of the buttons 92 and 94 causethe inner walls 96 to contact and moves inwardly the ridge portions 60and 64 of the tab portions 58 and 62 off the lip portion 82, therebydisengaging plug hinge 54 from slider hinge 70 and allowing foldingstructure 10 to be collapsed. Unlike conventional folding structures,buttons 92 and 94 provide a fast and easy means to release or disengagethe plug hinge 54 from the slider hinge 70, to allow collapse of thestructure 10.

Referring to FIGS. 3 and 9, the hinge mechanism 52 may further comprisea retaining plug 114. Retaining plug 114 generally comprises a housing114 having a lower portion 116 and a passageway or thru-hole 118.Retaining plug 114 is adapted to be inserted within base portion 56 ofplug hinge 54 [FIG. 3] to provide a means for retaining or securing theends of rope 106 within and to the plug hinge 54. After being threadedthru openings 104 of release cap, thru-hole 78 of slider hinge 70, andhole 57 of plug hinge 54, the end portions 108 of rope 106 are threadedthru the passage way 118 and tied into a knot 110 that will residewithin the lower portion 116. As upper portion 112 of rope 106 is pulledupwards, plug hinge 54 is brought into engagement with the slider hinge70, and the upper length of rope 106 may be left hanging or otherwiseunused.

The plug hinge 54, slider hinge 70, release cap 80, and retaining plug114 may be made from conventional plastic materials and fabricated byconventional molding processes. Legs 28, 30, 32, and 34 may be made fromconventional materials such as spring steel, plastic, metal rods andfabricated by conventional molding processes. Fabric enclosure 12 may bemade from conventional textile fabrics such as nylon and fabricated byconventional molding processes.

Many modifications and variations may become apparent in light of theabove teachings. By way of example only, in lieu of the flexible tabsthe plug hinge may include spring-loaded buttons that extend outwardfrom the plug hinge. The spring-loaded buttons may retract into the plughinge as it is pulled into the slider hinge. The slider hinge or releasecap may include detents into which spring-loaded buttons will extend asthe plug hinge reaches the extent of its travel into the hinge assembly,so as to lock the plug hinge in the hinge assembly. Release buttons onthe hinge assembly can then engage the spring-loaded buttons to forcethem back out of the detents and thereby release the plug hinge. Otherengagement means, including arrangements wherein the plug hinge mayengage about the outside of the hinge assemble are contemplated.Additionally, various arrangements of the support and extending arms maybe employed to provide various configurations to the folding structure.Further, the pulling means may be other than a rope or cord: e.g., aflexible rod, a ring, or other mechanism whereby the plug hinge andhinge assembly are moved toward one another for engagement. In short,the present invention may be embodied in other specific forms withoutdeparting from the spirit and/or scope of the specification and appendedclaims.

1. A folding structure comprising a plurality of legs and a hingemechanism, said hinge mechanism comprising a plug hinge engagable with aslider hinge between a first position in which the folding structure issubstantially collapsed, and a second position in which the foldingstructure is substantially open with said plug hinge locked to saidslider hinge to maintain the structure in its open position.
 2. Thefolding structure of claim 1, wherein said hinge mechanism furthercomprising a first button adapted to release said plug hinge from saidslider hinge to allow return of the structure to its folded position. 3.The folding structure of claim 2, wherein said plug hinge comprises afirst tab portion releasably engaged with said slider hinge.
 4. Thefolding structure of claim 3, wherein said slider hinge comprises a lipportion releasably engaged with said first tab portion of said plughinge.
 5. The folding structure of claim 4, wherein said first tabportion comprises a ridge portion removably connected with said firsttab portion of said plug hinge and depression of said first buttoncauses said first tab portion to be disengaged from said ridge portion.6. The folding structure of claim 5, wherein said first button comprisesan inner surface and depression of said first button causes said innersurface to push said ridge portion of said first tab portion off saidlip portion of said slider hinge.
 7. The folding structure of claim 6,wherein said plug hinge further comprises a second tab portion having aridge portion removably connected with said lip portion of said sliderhinge.
 8. The folding structure of claim 7, further comprises a secondbutton having an inner surface and depression of said second buttoncauses said inner surface of said second button to push said ridgeportion of said second tab portion off said lip portion of said sliderhinge.
 9. The folding structure of claim 8, wherein said first andsecond tab portions of said plug hinge are flexible and resilient. 10.The folding structure of claim 9, wherein said slider hinge comprises aninternal hole.
 11. The folding structure of claim 10, wherein said firstand second tab portions extend within said internal hole of said sliderhinge when said ridge portions of said first and second tab portions areengaged with said lip portion.
 12. The folding structure of claim 11,wherein said first and second tab portions are deflected upon saidinsertion into said internal hole of said slider hinge and said ridgeportions of said first and second tab portions snap into engagement withsaid lip portion of said slider portion.
 13. The folding structure ofclaim 12, further comprising a release cap engaged with said sliderhinge; said first and second buttons being formed as part of saidrelease cap.
 14. The folding structure of claim 13, wherein saidinternal hole of said slider hinge comprises a taped annular wall andsaid insertion of said first and second tab portions of said plug hingeinto said internal hole of said slider hinge causes said ridge portionsof said first and second tab portion to ride upon said tapered annularwall and deflect said first and second tab portions.
 15. The foldingstructure of claim 14, wherein each of said first and second tabportions comprise an upwardly extending tapered wall adapted to beinserted within said tapered annular wall of internal hole of saidslider hinge.
 16. The folding structure of claim 15, wherein said lipportion of said plug hinge is annular shaped.
 17. The folding structureof claim 16, wherein said ridge portions of said plug hinge are annularshaped.
 18. The folding structure of claim 17, wherein said first andsecond tab portions of said plug hinge are elongated and annular shaped.19. A method of folding and opening a structure comprising the steps of:(a) providing the structure with a plug hinge, a slider hinge, and arelease cap having a first button; (b) moving said plug hinge intolocked engagement with said slider hinge to hold the structure in theopen position; (c) depressing said first button to disengage said plughinge from said slider hinge; and (d) collapsing said folded structure.20. The method of claim 19, wherein said step of moving said plug hingeinto locked engagement with said slide hinge comprises the step ofpulling a rope connected to said plug hinge.